Reinforced pile fabric



y 1962 H. F. NOWICKI ETAL 3,034,541

REINFORCED PILE FABRIC Filed Jan. 22, 1959 2 Sheets-Sheet 1 FIG. I PK; 4

' INVENTORSZ HENRY E NOWICKI HARRY J. SMILEY ATTY y 1962 H. F. NOWICKIETAL I 3,034,541

REINFORCED PILE FABRIC Filed Jan. 22, 1959 2 Sheets-Sheet 2 FIGII. FIGIZINVENTORS: HENRY F NOWICKI HARRY J. SMILEY ATTY.

United States Patent Office 3,@34,541 Patented May 15, 1952 Thisinvention relates to woven pile fabrics in which the weft shots areinserted by means of a needle as distinguished from a shuttle. It is theparticular feature of the present invention to provide a fabric having arelatively heavy or stiff backing structure which not only improves thedesirability of the fabric, but also enhances tuft-bind and dimensionalstability.

The production of pile fabrics using a needle instead of a shuttle forthe insertion of the weft shots or picks is, of course, well known.Experience with this type of fabric has indicated the necessity for somestrengthening feature in order to produce satisfactory and saleablemerchandise. Heavy back-sizing and the lamination of a second wovenfabric have all been tried with varying degrees of success. The presentinvention overcomes the necessity for subsequent operations after theinitial weaving in that it produces a firm, heavy backing for any typeof velvet, Wilton, Brussels, or tapestry fabric.

A primary object of the invention, therefore, is to provide in a needleinserted double weft woven fabric a relatively heavy woven backing.

A further object of the invention is to provide in a fabric of the typedescribed a series of specially woven extra warps which enhance the pilebinding properties of the fabric.

A further object is to provide in a single shot needle insertion fabricmeans for insuring dimensional stability and tuft-bind.

A further object of the invention is to provide in a two shot needleinsertion fabric a stuifer warp carried between simultaneously insertedtop and bottom double weft shots.

A further object of the invention is to provide in a two shot needleinsertion fabric a stuffer warp interwoven with simultaneously insertedtop and bottom double weft shots.

A further object of the invention is to disclose the variouscombinations of pile effects that are desirably achieved in a fabricthat is constructed in accordance with the pres ent invention.

Further objects will be apparent from the specification and drawings inwhich:

FIGURE 1 is a schematic top view of a pile fabric constructed inaccordance with the present invention,

FIGURE 2 is an enlarged warp-wise section showing the fabric of FIGURE 1in both loop and cut pile,

FIGURE 3 is a weft-wise sectional detail as seen at 33 of FIGURE 2,

FIGURE 4 is an enlarged schematic top view showing a variation of thefabric of FIGURE 1,

FIGURE 5 is a warpwise section having both cut and uncut pile of thefabric of FIGURE 4,

FIGURE 6 is an enlarged sectional detail of the fabric of FIGURE 5 asseen at 6-6,

FIGURE 7 is an enlarged warpwise section of a single shot fabric havingboth cut and uncut pile and additionally a variation in the backingweave,

FIGURE 8 is an enlarged sectional detail as seen at 88 of FIGURE 7,

FIGURE 9 is an enlarged warpwise section of a single shot Wilton weaveembodying the present invention,

FIGURE 10 is an enlarged sectional detail as seen at 10-10 of FIGURE 9,

FIGURE 11 is an enlarged warpwise section of a velvet pile fabric havingboth out and uncut pile showing the invention as applied to a two shotfabric with stuifer p,

FIGURE 12 is an enlarged sectional detail as seen at 12-12 of FIGURE 11,

FIGURE 13 is an enlarged warpwise section of a velvet fabric constructedin accordance with the invention having modified arrangement of stufferwarps,

FIGURE 14 is an enlarged sectional detail as seen at 1414 of FIGURE 13,

FIGURE 15 is an enlarged warpwise section of a velvet fabric having bothout and uncut pile using a different reinforcing ground fabricconstruction,

FIGURE 16 is an enlarged sectional detail as seen at 1616 of FIGURE 15,

FIGURE 17 is an enlarged warpwise section of a two shot Wiltonconstructed in accordance with the invention, and

FIGURE 18 is an enlarged sectional detail as seen at 18-18 of FIGURE 17.

The invention comprises essentially the provision of a reinforcing meansfor the ground or base fabric in a non- Axminster pile weave butproduced with double wefts on a loom having a needle motion asdistinguished from a shuttle motion. The one shot fabric utilizescertain interwoven extra warps to achieve dimensional stability and toprovide a stronger base fabric. The double needle fabric utilizes aweave having simultaneously inserted upper and lower double fillingwefts.

Referring now more particularly to the drawings, the velvet pile fabricshown in FIGS. 1-3 comprises a plurality of double filling wefts 20, 20which are positioned in substantially the same horizontal plane. Thepile wires 21 over which the pile warps 22 and 23 are woven are insertedwith each one of the double filling wefts 2% In the fabric shown inFIGURE 1 there is only one end of pile yarn in each dent which may bedefined by the space between double chain warps 25 and stutfer warps 26.As seen in FIGURE 1, the double chain warps 25 and 25a weave opposite toeach other which means that they are controlled by separate harnessframes and they weave alternately over and under successive fillingwefts 29. The pile end 23 weaves over and under successive wefts 29whereas the pile end 22 weaves over and under intermediate wefts 20, 20.This provides the weftwise staggered weave shown clearly in FIGS. 1 and2. Ordinarily a one shot or single plane pile fabric requires anadditionally adhered material such as scrim, a foam rubber backing, orrelatively stiff backsizing to achieve the desired dimensionalstability. We propose, however, to increase the stability of the fabricand to reinforce the fabric backing by using the double chain warps 25and 25a together with additional stuffer warps 26 and 27. These stufferwarps are double and weave under and over successive pairs of fillingwefts 20, 26 but at least one of the stufier warps 26 or 27 is separatedfrom the pile yarn 23 by means of an oppositely weaving binder 25.Likewise stuflfer 26 is separated from pile warp 22 by binder warp 25a.The tendency of the double weaving of stutter warp 26 to twistsuccessive filling wefts 29 and thereby hold them in a substantiallystraight plane is well pronounced. This is an important feature of theinvention. It will also be apparent that between every row of pile yarns22 and 23 there is woven at least two double warps one of which weavesover and under each succeeding filling weft and the other of whichweaves over and under successive pairs of double filling wefts.

In FIGURE 4 the reinforcing of the base or ground fabric is accomplishedby the addition of a single relatively heavier stutter '30 which weavesunder and over pairs of filling wefts 20. On either side of the stuffer30 we provide chain or hinder warps 31 and 32 which weaves over andunder successive filling wefts 20, but which are spaced apart from eachother. The above weaving of the warps in each dent is identical, but itwill be noted that the innermost binder warps 33 and 31 work together sothat they are simultaneously over and under the same filling shot. Againit is to be noted that the adjacent double and single weaving of theground warps in a dent is a very important factor in providing greaterdimensional stability. In this form it is desirable to use double pileends working together over and under successive wefts. FIGURE 4 alsoillustrates a variation in the pile projections which are formed fromdouble warps 22 and 23.

Where even further reinforcing of the ground fabric is indicated, it ispossible to achieve this result by using two cotton binder warps 35, 35workin together and opposite to a pair of warps 36 (FIG. 8). Thisconstruction is also repeated between successive pairs 37 and 38 of thepile loop projections. This fabric lends itself to both velvet andWilton construction (as seen in both FIGURES 7 and 9, the former beingvelvet) since the weave is one in which there is no selection of thepile ends working over the wires except as may be achieved by means ofconventional harness frames. In FIGURE 9 there is shown'a one shotWilton weave having pile wires 21 inserted on each double filling weft20 but in which some of the pile yarns, for example pile yarn 40, rundead on the back of the fabric as shown at float 41. The pile yarn 42 islikewise controlled by a jacquard, not shown, so that either or both ofthe yarns may be selected to weave over any one of the set of pile wires21. In the Wilton weave there are single opposed binder warps 43 and 44which run in each dent and which are separated from the pile yarns and42 by means of a relatively heavier stufier warp 45. The stufier warp 45may weave over and under successive filling wefts 20 or it may becarried over two or more successive filling wefts as shown in the velvetweave of FIGURE 5 By judicious selection of the place and length of theback floats 41, added reinforcing and stiffening for the ground fabricis achieved. The weaving of two pile warp ends per dent contributes tothe general stability of the fabric. In FIGS. 2, 5, and 7, the cut pileis illustrated at C and the uncut or loop pile is shown at L. It will beunderstood that any particular fabric may be all cut, all uncut, orpartly cut and partly uncut.

A further manner in which a needle or double weft pile fabric may bereinforced involves the provision of simultaneously inserted top andbottom double filling wefts and 51. These wefts are inserted betweenreversals of the harness frames so that the opposed single binder warps52 and 53 compress the top and bottom wefts 50 and 51 against thestulfer warps 54. FIGURE 12 shows a four ply stuifer warp 54, but itwill be understood that the stutfer warp may be single or any number ofseparate yarn ends. The weaves shown in FIGS. 11 and 12 illustrate cutand uncut pile areas in a velvet weave having two oppositely workingpile yarns per dent. In FIGURES 13 and 14, the single heavy stufier 55weaves over and under successive upper double wefts 50 and a secondoppositely working single heavy stuifer 56 also weaves over and underthe top wefts 50, but the stuffers 55 and 56 split the pile yarns ineach dent. V

An alternative manner in which the backing of the pile fabric may bereinforced is shown in FIGS. 15 and 16 which utilize in addition to thebinder warps 52 and 53, one or more heavy reinforcing or stuifer warps60, 61, 62, and 63. These reinforcing warps may work side by side andweave together over pairs of double filling wefts or they may split thepile warps 64 and 65 as shown, clearly in PEG. 16. The fabric of FIGS.15 and 16 is what might be called a hybrid fabric since the upper andlower filling wefts 50 are not separated by a staffer, but the so-calledstutfer warps 6l63 weave over and under double pairs of the fillingwefts to provide what is in effect an extra heavy single plane fabric.It will also be noted that the pile warps 64 and 65 weave through to theback as is the case with the ordinarily single plane or one shot fabric.

FIGURES 11l6 illustrate various forms of a reinforced velvet pile fabricwhereas FIGURES 17 and 18 show a two shot Wilton fabric with doubleneedle, double weft insertion. Here again the upper wefts 50 and thelower wefts 51 are inserted simultaneously and are separated by the fourply stuifer as well as the pile warps 71 and 72. The single opposedbinder warps 73 and 74 weave over and under, a single upper and lowerfilling weft 50 and 51. The pilewarps 71 and 72 are shown in the form ofhigh floats 75 and running dead in the fabric at 76.

It will thus be understood that we have provided an improved reinforcingfor needle inserted double weft woven fabric which achieves adequatedimensional stability for utilizing an extraneous backing material orbacksize.

Having thus described our invention, we claim:

1. A single plane one shot woven pile fabric comprising a plurality ofdouble filling wefts in spaced co-planar relation to each other, rows ofparallel pile yarns interwoven with said filling wefts and forming pileprojections on only one side of said co-planar wefts, pairs of binderwarp being interwoven with said filling. wefts, at least one reinforcingground warp of greater diameter than.

the pairs of binder warps running with the binder warps and beinginterwoven with said filling wefts, said pairs of binder warps and saidreinforcing warp being spaced weftwise of the fabric between at leastevery second row of pile yarn.

2. A fabric in accordance with. claim 1 in which the reinforcing groundwarp interweaves with pairs of double filling wefts.

3. A fabric in accordance with claim 2 in which the binder warpsinterweave with every double filling weft.

4. A fabric in accordance with claim 1 having pair of opposed adjacentbinder warps interweaving with every double filling weft.

References Cited in the file of this patent UNITED STATES PATENTS111,325 Crompton Ian. 31, 1871 1,341,417 Davis May 25, 1920 2,578,173Clark Dec. 11, 1951 2,647,546 Ryan Aug. 4, 1953 2,715,918 Eisler et alAug. 23, 1955 2,760,528 McKnight et a1 Aug. 28, 1956 2,860,669 MobergNov. 18, 1958

